ERT 455 MANUFACTURING &

PRODUCTION OF BIOLOGICAL PRODUCT

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Topic Outline

Introduction and GoalsIntroduction and Goals Food Spoilage and Foodborne Food Spoilage and Foodborne

DiseaseDisease Product Formulations and Flow Product Formulations and Flow

ChartsCharts Units of OperationsUnits of Operations Processing and Preservation Processing and Preservation

TechniquesTechniques Packaging Packaging 2

1.5 Processing and Preservation Techniques

Several MethodsSeveral Methods Heat applicationHeat application Cold preservationCold preservation Evaporation and dryingEvaporation and drying Food additivesFood additives Fermentation Fermentation

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1.5 Processing and Preservation Techniques

1.5.4 Food Additives1.5.4 Food Additives substances added substances added to food to preserve flavor or

enhance its taste and appearance.

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To maintain product consistency.To maintain product consistency. EmulsifiersEmulsifiers – consistent texture and prevent

from separating. StabilizersStabilizers – used to retain the physical

characteristics of the food . AnticakingAnticaking agentsagents – help substances such as

salt to flow freely @ to prevent the formation of lumps, easing packaging, transport, and consumption.

To improve nutritional value.To improve nutritional value. Added vitamins and minerals – milk, flour,

cereal and margarine.

1.5 Processing and Preservation Techniques

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To improve nutritional value.To improve nutritional value. AntioxidantsAntioxidants – – prevent fats and oils in baked goods. - prevent cut fresh fruits from turning

brown when exposed to air (apple).

To provide leavening.To provide leavening. Leavening agents, release acids when heated –

helps cakes, biscuits and etc to rise during baking. To enhance flavor. To enhance flavor.

Spice and synthetic flavor – enhance taste of foods. Impart desired color.Impart desired color.

Color – enhance the appearance.

1.5 Processing and Preservation Techniques

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Two types.Two types.

1.5 Processing and Preservation Techniques

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Direct AdditiveDirect Additive Substance is added to a food for a specific purpose in that food.

Eg: sugar or salt. .

Indirect additivesIndirect additives Substances that may come into contact with food as part of

packaging or processing equipment, but are not intended to be added directly to food.

1.5 Processing and Preservation Techniques

Color AdditiveColor Additive Any dye, pigment or substance Any dye, pigment or substance that can impart

color when added or applied to a food, drug/cosmetic or human body.

Used in foods, drugs, cosmetics, and medical devices (contact lenses).

ReasonReason. To offset color loss due to storage/processing. To correct natural variations in food color.

Can derived from natural sources. Vegetables, minerals, or animals. Eg: caramel color – produced by heating sugar.

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1.5 Processing and Preservation Techniques

1.5.5 Fermentation1.5.5 Fermentation Had been developed since ancient times. In food processing, fermentation typically is the

conversion of carbohydratesconversion of carbohydrates to alcohols and to alcohols and carbon dioxide or organic acids carbon dioxide or organic acids using yeasts, bacteria, or a combination thereof, under anaerobic conditions.

Prepared/derived from.. Dairies, grains, fruits, vegetables, muscle foods and etc.9

Simple understanding..

Fermentation is the chemical conversion of sugars into ethanol.

5 main purposes5 main purposes Enrichment of the diet Enrichment of the diet through development of through development of

a diversity of flavors, aromas, and textures in a diversity of flavors, aromas, and textures in food substrates.food substrates.

PreservationPreservation of substantial amounts of food of substantial amounts of food through lactic acid, alcohol, acetic acid and through lactic acid, alcohol, acetic acid and alkaline fermentations.alkaline fermentations.

Biological enrichment Biological enrichment of food substrates with of food substrates with protein, essential amino acids, essential fatty protein, essential amino acids, essential fatty acids, and vitamins.acids, and vitamins.

Elimination of Elimination of antinutrients.antinutrients. Decrease in Decrease in cooking times cooking times and and fuel fuel

requirementsrequirements.. 10

1.5 Processing and Preservation Techniques

Primary benefit Primary benefit – conversion of sugars and – conversion of sugars and others carbohydrates . Examples: others carbohydrates . Examples: Juice into wineJuice into wine Grain into beerGrain into beer carbohydrates into carbon dioxide to leaven carbohydrates into carbon dioxide to leaven

breadbread Sugars in vegetables into preservatives organic Sugars in vegetables into preservatives organic

acids.acids.

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1.5 Processing and Preservation Techniques

PACKAGING

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Generally, to Generally, to protect the foodprotect the food so its so its elements will not be exposed until it is elements will not be exposed until it is ready to be prepared and consumed.ready to be prepared and consumed.

Prepared from Prepared from different materials.different materials.

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1.6 Packaging

Glass

Paper based

Metal can

Plastic

Functions of food packagingFunctions of food packaging Physical protection Physical protection – – shock, temperature, shock, temperature,

compression.compression. Barrier protection Barrier protection – – water vapor, dust, oxygen. water vapor, dust, oxygen.

Some packaging have oxygen absorber to help Some packaging have oxygen absorber to help extend shelf life.extend shelf life.

ContainmentContainment – – reason of efficiency (powders and reason of efficiency (powders and granular materials need containment).granular materials need containment).

Information transmission. Information transmission. Marketing.Marketing. Convenience.Convenience. Portion control.Portion control.

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1.6 Packaging

Food packaging types.Food packaging types.

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1.6 Packaging

Type Food example

Cans Can of Tomato soup

Plastic tray Fish, meat

Bags Potato chips

Flexible packaging Bagged salad

Cartons Eggs

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Bag in box-aluminum foil-paperboard

Blister pack-aluminum foil-thermoformed plastic

1.6 Packaging

Aluminum can-aluminum

Shelf-lifeShelf-life Shelf-life of packaged foods is controlled Shelf-life of packaged foods is controlled

by:by:

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1.6 Packaging

Food properties

Water activity pH

Sensitivity Microbiologicaldeterioration

Barrier properties

The ability of a package to control the permeation and penetration of gasses

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1.6 Packaging

EnvironmentAdulteration

Contamination

Physical/Chemical

deterioration

Temperaturechange

Factors affecting the selection of a Factors affecting the selection of a packaging material.packaging material. LightLight – deterioration by light = changes in – deterioration by light = changes in

color caused by loss of natural pigmentscolor caused by loss of natural pigments Temperature Temperature – low thermal conductivity – low thermal conductivity

materials = reduce conductive heat transfer.materials = reduce conductive heat transfer. Mechanical strength Mechanical strength – protect from damage.– protect from damage. Grease resistance Grease resistance – leakage of oils and fats – leakage of oils and fats

spoil the appearance of a pack.spoil the appearance of a pack. Micro-organisms, inserts, animals and soils – Micro-organisms, inserts, animals and soils –

inadequate seals, inadequate seals, tears = contaminationtears = contamination 19

1.6 Packaging

Packaging materials for selected foodsPackaging materials for selected foods..Short shelf-lifeShort shelf-life

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1.6 Packaging

Medium/ long shelf-lifeMedium/ long shelf-life

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1.6 Packaging

Medium/ long shelf-lifeMedium/ long shelf-life

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1.6 Packaging

Interactions between packaging and foods.Interactions between packaging and foods. 2 reasons2 reasons

May have toxicological effects on the consumer.May have toxicological effects on the consumer. Reduce the shelf-life or sensory quality of the food.Reduce the shelf-life or sensory quality of the food.

Some types of packaging materials have Some types of packaging materials have volatile compounds that may be absorbed and volatile compounds that may be absorbed and cause tainting of foods.cause tainting of foods.

In metal containers, interaction of food acids, In metal containers, interaction of food acids, anthocyanins, sulphur compounds and etc with anthocyanins, sulphur compounds and etc with steel, tin or aluminum are prevented by using steel, tin or aluminum are prevented by using lacquers and coatings for the metal.lacquers and coatings for the metal.

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1.6 Packaging

Assignment Task Find Find issueissue in designing packaging for in designing packaging for

biological products.biological products. Example: Example:

Changing of the drinking glass bottle packaging into Changing of the drinking glass bottle packaging into plastic bottle packaging.plastic bottle packaging.

Effect of drinking water in plastic bottle when exposed Effect of drinking water in plastic bottle when exposed to the high temperature.to the high temperature.

DiscussesDiscusses,, ProblemsProblems that occurred. that occurred. EffectsEffects to the human life. to the human life. Suggestion of the Suggestion of the solutions, additions or improvements solutions, additions or improvements

that can be done.that can be done.24

THANK YOU FOR YOUR ATTENTION…

References : References :

José M. Aguilera and Peter J. Lillford, José M. Aguilera and Peter J. Lillford, Food Materials ScienceFood Materials Science ¸ Springer Science+Business ¸ Springer Science+Business Media, LLC ¸2008Media, LLC ¸2008

Hui., Y.H., Hui., Y.H., Handbook of Food Products ManufacturingHandbook of Food Products Manufacturing, Wiley & Sons, Inc., Hoboken, New , Wiley & Sons, Inc., Hoboken, New Jersey, 2007Jersey, 2007

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